Power Integrations has just unveiled a game-changing flyback topology that pushes flyback converters to 440W, well beyond the traditional limits that typically force designers to adopt more complex resonant or LLC topologies.
The new TOPSwitchGaN™ flyback IC family combines the company’s cutting-edge PowiGaN™ technology with its proven TOPSwitch™ architecture. The result is simpler designs, no heat sinks in many cases, faster development, better manufacturability, and lower overall system costs.
These ICs deliver an impressive 92% efficiency across the full 10-100% load range and easily meet European ErP regulations with under 50mW standby/off-mode consumption, no synchronous rectification required. They’re perfect for high-end appliances, e-bike chargers, and industrial power supplies.
Why PowiGaN Makes This Possible
PowiGaN switches offer dramatically lower RDS(ON) than silicon, slashing conduction losses and unlocking much higher power levels for flyback designs.
With 800V PowiGaN switches built in, these devices provide excellent surge protection and low switching losses, enabling frequencies up to 150kHz for ultra-compact transformers.
No-load consumption stays below 50mW at 230VAC (including line sense), and up to 210mW output power is available at 300mW input for standby housekeeping functions.
Flexible Packaging for Any Design
Power Integrations offers two package options:
- eSOP™-12(low-profile surface-mount) for ultra-slim designs, delivering 135W (85–265VAC) without a heat sink—ideal for appliances.
- eSIP™-7(vertical package) minimizes PCB footprint with TO-220-equivalent thermal performance. Add a simple clip-on metal heat sink, and you’re set for 440W applications like power tools, e-bikes, and garage door openers.
Best of all, TOPSwitchGaN ICs are pin-to-pin compatible with TinySwitch™-5 switchers, so engineers can use the same design methodology across power levels from 10W to 440W.
Leadership Comments
“This is more than a product evolution, it’s a fundamental shift in how engineers can approach power supply design,” said Silvestro Fimiani, director of product marketing at Power Integrations. “For decades, designers have had to move to resonant topologies like LLC as power levels increased. With TOPSwitchGaN, we’re pushing flyback into a power range previously not possible, allowing engineers to achieve high efficiency and performance with a far simpler architecture.”
Fimiani continued: “As the first device to combine offline switchers into small packages and with billions of units sold since 1994 the TOPSwitch name stands for innovation in power conversion. Engineers rely on TOPSwitch for its efficiency and ease of use, and now those benefits are available for an even wider range of designs. TOPSwitchGaN expands the power range of the flyback architecture to 440 W—previously unheard of using a flyback architecture—expanding the use of flybacks into applications previously requiring more complex topologies.”
